Recycling success in Catalonia for Kleemann

ADEC Global use Kleemann crushing and screening equipment in challenging waste-recycling application

BARCELONA-based ADEC Global are a renowned player in the Catalonian recycling sector, processing waste materials from the local construction market and steelworks. Today, the business recycles around 500,000 tonnes of waste annually, 50% of which is highly abrasive slag contaminated with steel. 

‘We are converting waste materials that used to end up in landfills into valuable recycled products,’ said Maria Vazquez, operations manager at ADEC Global. ‘At the heart of our waste-processing operation are the Kleemann Mobirex MR 110 EVO2 impact crusher and Mobiscreen MSS 802 EVO coarse screening plant, which are processing slag into aggregates for asphalt.’

ADEC Global are no stranger to operating Kleemann mobile equipment – the company currently has a total of 11 Kleemann machines, and in addition to its recycling operation, it produces and supplies various aggregate products for the concrete and cement markets using a Mobirex MR 130 PRO impact crusher.

‘Together with Kleemann and EMSA, our local contact for Kleemann machinery, we have developed an ideal process to tackle and reprocess extremely challenging waste materials,’ explained Fernando Hernandez, managing director and founding partner at ADEC Global. ‘Wear parts are a real challenge too. How can the impact bars withstand the abrasive material and achieve a long service life without breaking? How can we make the process safer?’ 

Looking for help in identifying a waste-recycling solution, ADEC Global once again turned to Kleemann and invested in the Mobirex MR 110 EVO2 mobile plant and Mobiscreen MSS 802 EVO mobile coarse screening unit.  

Oscar Hernandez, who is responsible for machinery and logistics at ADEC Global, said he is extremely impressed with the robust design of Kleemann aggregate processing plants and parts. 

‘There are very few machines out there that can withstand the extremely abrasive material we take on,’ said Oscar Hernandez. ‘The slag contains iron deposits that are broken down during the crushing process. Even so, the Kleemann impact crusher remains steadfast. I don’t know of any other brand of equipment that can handle this and ensure separated iron components are also returned to the foundries, achieving 100% recycling.’

The Kleemann Mobirex MR 110 EVO2 impact crusher has been in operation for a few years and is still performing well for ADEC Global, having already logged 10,000 hours of work time. It processes feed material measuring up to 200mm and produces 200 tonnes of recycled materials per hour under optimal conditions. 

A magnetic separator separates the metal from the slag as the final step. Sophisticated uptime features such as the overload system, which reacts immediately to material jamming, protect the crusher, contributing to the smooth and efficient operation of the entire crushing process.

The Mobirex MR 110 EVO2 not only delivers impressive crushing performance but also remarkably low fuel consumption of just 19 litres per hour. ‘The plants we had in the past consumed significantly more than that,’ recalled Fernando Hernandez. 

The Mobiscreen MSS 802 EVO screening plant is primarily used to clean waste material and prepare it for feeding to the impact crusher. ‘The dual-power drive gives us the option of operating the plant with electricity in the future, which means zero CO₂ emissions locally,’ said Fernando Hernandez. 

The fact that highly abrasive materials, in this case, contaminated black slag, can now be processed efficiently and cost-effectively is due to the excellent teamwork between ADEC Global employees responsible for the process and Kleemann’s application experts. It was through collaboration that a cost-effective recycling solution for achieving high-quality products with this difficult material could be found and delivered.